Battery cell interconnect and methods of manufacture thereof

ABSTRACT

A battery cell includes a cathode casing forming all or a majority of the external can of the battery cell. The battery further includes an anode tab covering at least a portion of a face of the battery cell and an insulating layer for electrically isolating the anode tab from the cathode casing. A plurality of such battery cells may be arranged within a battery pack in contact with each other, and may be held in compression. A conduction enhancement layer may be applied between the anode tab of a first cell and the cathode casing of a second cell within the battery pack. One or more heat dissipation elements may be arranged within the battery pack, in contact with the battery cells.

This application is a divisional of U.S. patent application Ser. No.15/702,660, filed Sep. 12, 2017, which claims benefit of priority toU.S. Provisional Application No. 62/398,427, filed Sep. 22, 2016, whichare hereby incorporated by reference in their entirety.

BACKGROUND

Battery packs are presently used to provide electrical power to numerousdevices, including tools, vehicles, laptop and tablet computers, andmobile phones. In many applications, the physical space required for thebattery pack or packs is a crucial design consideration that affectsmany aspects of a product, including physical size and shape andperformance. For example, the available operational time of a portableelectronic device and the physical range of an electronic vehicle areboth directly affected by the volume of space available to the batterypack and the efficiency of usage of the available volume. In manybattery pack applications, it is desirable to safely and efficientlymaximize usage of battery pack volume, for example to add electricalcapacity to the product, reduce the battery pack size, or to allow formore efficient cooling of a battery pack.

A common type of battery is a rechargeable battery with a lithium-basedchemistry—for example, a lithium-ion or a lithium-polymer battery.Lithium-ion and lithium-polymer batteries typically contain a cathodecurrent collector; a cathode comprised of an active material, aseparator, an anode current collector; and an anode comprised of anactive material. The cathode can comprise a cathode coating, and theanode can comprise an anode coating. The cathode, separator, and anodeassembly is typically assembled in a cylindrical or prismatic “jellyroll” configuration within a battery casing, with conducting anode andcathode conducting terminals, arranged to protrude into itscorresponding active material and allow for a point of electricalconnection external the battery casing. A battery casing of existingbatteries may typically be neutral, but also may be at cathode(positive) potential or anode (negative) potential.

Existing battery packs typically use a bus bar or another similar meansincluding one or more conductor separate from the battery cells, whichis usually welded to terminals of a battery cell to form aninterconnection system. The bus bar and similar interconnection systemsconsume space within a battery pack that could be used for otherpurposes if a more efficient battery interconnect system were to beimplemented.

SUMMARY

A battery cell is configured to maintain electrical communication withother battery cells within a battery pack by being in physical contactwith one or more other cells within the pack. A battery cell includes acathode casing forming all or a majority of the external can of thebattery cell. The battery further includes an anode tab covering atleast a portion of a face of the battery cell and an insulating layerfor electrically isolating the anode tab from the cathode casing. Aplurality of such battery cells may be arranged within a battery pack incontact with each other, and may be held in compression. A conductionenhancement layer may be applied between the anode tab of a first celland the cathode casing of a second cell within the battery pack.

Some embodiments include one or more fuses integrated with the anode tabor as part of the cathode casing. One or more heat dissipation elementsmay be arranged within the battery pack, in contact with the batterycells. Some embodiments include a flexure section built into the anodetab, for example to accommodate a compression force holding a string ofbattery cells in physical contact.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross section of an example battery pack includingthree cells configured to implement an interconnect according to someembodiments.

FIG. 2 illustrates a cross section of two battery cells in electricalcommunication according to some embodiments.

FIG. 3A is an isometric external view of a battery cell including ananode tab according to some embodiments.

FIG. 3B is an another isometric external view of the battery cell ofFIG. 3A according to some embodiments.

FIG. 3C is an isometric external view of three battery cells in seriescontact according to some embodiments.

FIG. 4A is an isometric external view of an additional example batterycell according to some embodiments.

FIG. 4B is another isometric external view of the battery cell of FIG.4A according to some embodiments.

FIG. 4C is another isometric external view of three example batterycells in series contact according to some embodiments.

FIG. 5A illustrates a cross section of a battery cell in contact with acold plate according to some embodiments.

FIG. 5B illustrates a cross section of a battery cell in contact withmultiple cold plates according to some embodiments.

FIG. 6A illustrates a cross section of a battery cell including a fuseaccording to some embodiments.

FIG. 6B illustrates a cross section of a battery cell including adischarge element according to some embodiments.

FIG. 7 is a high-level flowchart illustrating various methods offabricating a battery cell according to some embodiments.

This specification includes references to “one embodiment” or “anembodiment.” The appearances of the phrases “in one embodiment” or “inan embodiment” do not necessarily refer to the same embodiment.Particular features, structures, or characteristics may be combined inany suitable manner consistent with this disclosure.

“Comprising.” This term is open-ended. As used in the appended claims,this term does not foreclose additional structure or steps. Consider aclaim that recites: “An apparatus comprising one or more processor units. . . .” Such a claim does not foreclose the apparatus from includingadditional components (e.g., a network interface unit, graphicscircuitry, etc.).

“Configured To.” Various units, circuits, or other components may bedescribed or claimed as “configured to” perform a task or tasks. In suchcontexts, “configured to” is used to connote structure by indicatingthat the units/circuits/components include structure (e.g., circuitry)that performs those task or tasks during operation. As such, theunit/circuit/component can be said to be configured to perform the taskeven when the specified unit/circuit/component is not currentlyoperational (e.g., is not on). The units/circuits/components used withthe “configured to” language include hardware—for example, circuits,memory storing program instructions executable to implement theoperation, etc. Reciting that a unit/circuit/component is “configuredto” perform one or more tasks is expressly intended not to invoke 35U.S.C. § 112(f), for that unit/circuit/component. Additionally,“configured to” can include generic structure (e.g., generic circuitry)that is manipulated by software and/or firmware (e.g., an FPGA or ageneral-purpose processor executing software) to operate in manner thatis capable of performing the task(s) at issue. “Configure to” may alsoinclude adapting a manufacturing process (e.g., a semiconductorfabrication facility) to fabricate devices (e.g., integrated circuits)that are adapted to implement or perform one or more tasks.

“First,” “Second,” etc. As used herein, these terms are used as labelsfor nouns that they precede, and do not imply any type of ordering(e.g., spatial, temporal, logical, etc.). For example, a buffer circuitmay be described herein as performing write operations for “first” and“second” values. The terms “first” and “second” do not necessarily implythat the first value must be written before the second value.

“Based On.” As used herein, this term is used to describe one or morefactors that affect a determination. This term does not forecloseadditional factors that may affect a determination. That is, adetermination may be solely based on those factors or based, at least inpart, on those factors. Consider the phrase “determine A based on B.”While in this case, B is a factor that affects the determination of A,such a phrase does not foreclose the determination of A from also beingbased on C. In other instances, A may be determined based solely on B.

DETAILED DESCRIPTION

The systems and methods described here may implement battery cellinterconnection.

FIG. 1 illustrates a cross section of an example battery pack includingthree cells configured to implement an interconnect according to someembodiments. Battery pack 100 may include cells 160 a-160 c according tosome embodiments. Other embodiments may include any number of cells 160depending on specific requirements of the application (e.g. an electricvehicle or handheld electronic device) for which the battery pack ismeant. Cells 160 may be connected in any combination of series orparallel connections according to a particular desired voltage andenergy capacity configuration.

According to some embodiments, at least one cell 160 a-160 c includes aconductive tab 120 a-120 c, respectively. Tabs 120 a-120 c in a typicalembodiment may be an anode (positive) tab connected to one or more anodeprotrusions of its respective battery cell. In other embodiments, tabs120 a-120 c may instead be at cathode potential. In the exampleembodiment of FIG. 1 , a tab 120 may be electrically connected to activematerial of the cell through a top face of a cell 160 and protrudearound the exterior of the cell 160 to form a planar tab. In the exampleembodiment of FIG. 1 , cells 160 a-160 c are rectangular in shape andtabs 120 a-120 c may include a right angle around one corner theexterior of the respective cell. In some embodiments according to FIG. 1, a tab 120 a-120 c may cover a majority of the exterior of at least oneface of the respective cell 160.

One or more of cells 160 a-160 c according to some embodiments furtherinclude a cell casing (or external can) 130 a-130 c. According to someembodiments, all or a majority of the cell casing 130 of a particularcell may be at cathode potential. In other embodiments, the polarity ofthe cell casing 130 and the tab 120 may be reversed such that the tab120 becomes a cathode tab and the cell casing 130 is at anode potential.

According to some embodiments, a cell casing 130 may form all or amajority of the surface area of the external can or container of thecell. In other embodiments, the cathode potential portion may be furtherlimited, for example to a majority of one face of the cell opposite atab 120.

Configuring a cell casing 130 as a conductor at an anode or cathodepotential may allow for more efficient cooling opportunities, as furtherdescribed herein with reference to FIGS. 5A and 5B. For example, alarger conductive surface area as a result of such an arrangement asshown and described with reference to FIG. 1 and elsewhere herein mayallow for a more efficient heat sink, resulting for example in reducedthermal concentration within a battery cell or reduced overall operatingtemperatures. Both of those conditions may prolong the operational lifespan of a battery cell or its components, such as active material,separators, insulation, electrolyte seals, etc.

Insulating layers 110 a-110 c may be applied to electrically isolate atab 120 from a cell casing 130. An insulating layer 110 may include, forexample, a suitable polymer formed or applied around the desiredsections. Any substance having current inhibiting properties may beappropriate to form an insulating layer, as one of ordinary skill willunderstand. In the example embodiments of FIG. 1 , insulating layers 110a-110 c are shown between respective cell casings 130 a-130 c and tabs120 a-120 c on at least one face of the battery and a portion of the topof the battery.

At least a portion of one face of a battery cell 160 a-160 c may be leftuncovered by an insulating layer in order to allow for electricalcommunication with another cell by being positioned in physical contactwith an adjacent cell. For example, in the embodiment shown in FIG. 1 ,tab 120 a of cell 160 a physically contacts cell casing 130 b of cell160 b without an intervening insulating layer. Assuming tab 120 a isconfigured at an anode potential of cell 160 a and cell casing 130 b isconfigured at a cathode potential of cell 160 b, this physical contactforms a series electrical connection between cells 160 a and 160 b.

Current collectors 140 and 150 according to some embodiments may formelectrical terminals of pack 100. For example, current collector 140 maybe electrically coupled to a cathode potential of a string of batterycells 160 a-160 c. Current collector 150 according to some embodimentsmay be electrically coupled to an anode potential of a string of batterycells 160 a-160 c. In other embodiments, the polarity of currentcollectors 140 and 150 may be reversed.

Pack casings 170 and 180 according to some embodiments may form anexternal enclosure of pack 100. In some embodiments, pack casings 170and 180 may be formed of any suitable material, for example anonconductive plastic or polymer. Pack casings 170 and 180 may in someembodiments be two faces of a continuous enclosure, or may be physicallyseparate faces or plates, as shown in the embodiment of FIG. 1 .

Current collectors 140 and 150 according to some embodiments may formthe exclusive or primary conducting terminals of a pack 100. In someembodiments, current collectors 140 and 150 may protrude from orotherwise be exposed by an opening in a pack casing of pack 100. Theexample of FIG. 1 illustrates current collector 140 protruding throughan opening in pack casing 170 and current collector 150 protrudingthrough an opening in pack casing 180.

Cells 160 a-160 c according to some embodiments may be held incompression in physical contact with one another. For example, packcasings 170 and 180 may be arranged in some embodiments to provide acompressing force to a string of cells 160 a-160 c. In some embodiments,current collector 140 and current collector 150 may act as compressionplates in combination with or in lieu of compression provided by packcasings 170 and 180. Other embodiments may use a compression plate orstrap (not shown) separate from pack casings 170 and 180 or currentcollectors 140 and 150 to provide compressive force to a string ofbattery cells 160 a-160 c.

A compressive force applied to a string of battery cells according tosome embodiments may increase efficiency or reliability of theelectrical connections between the string of battery cells 160 a-160 c.In some embodiments, a pressure-sensitive adhesive layer may be appliedbetween various components of battery pack 100 to increase mechanicalstrength or reliability of the battery pack. For example, an adhesivesuch as a pressure-sensitive adhesive (“PSA”) may be applied between tab120 a and cell casing 130 b—or between similar components of any cellsin a battery string—according to some embodiments. In other embodiments,an adhesive may be applied between current collectors 140 and 150 orpack casings 170 and 180 and adjacent cells, or between an insulatinglayer and a tab 120 or cell casing 130.

FIG. 2 illustrates a cross section of two battery cells in electricalcommunication according to some embodiments. Example cells 260 a and 260b may include respective tabs 220 a-220 b, cell casings 230 a-230 b, andinsulating layers 210 a-b similar to those respective features asdescribed in detail with reference to FIG. 1 .

A conductive layer 270 a-270 b may be applied to a face of a respectivetab 220 a-220 b. For example, a conductive layer 270 a may be appliedbetween tab 220 a of cell 260 a and cell casing 230 b of cell 260 b toimprove electrical conductivity between cells 260 a and 260 b. In someembodiments, a conductive layer 270 a-270 b may be applied to arespective tab 220 a-220 b or to a portion of respective cell casing 230a-230 b during fabrication of a respective cell 260 a-260 b.

A conductive layer 270 a-270 b may be a conduction aid material, forexample Penetrox®. According to some embodiments, a conductive layer 270a-270 b may comprise a metallic or alloy plating. In other embodiments,a conductive layer 270 a-270 b may comprise any suitable material forenhancing or promoting electrical conduction, we would be apparent to aperson having ordinary skill in the art.

According to some embodiments, one or more of cells 260 a-260 b mayfurther include one or more respective feed-throughs or penetrations 250a-250 c, which protrude into the interior of the respective cell. Afeed-through or penetration 250 a-250 b may be a conducting material inelectrical or physical contact with active material of a respective cell260 a-260 b. For example, one or more of feed-throughs or penetrations250 a-250 b may contact anode active material of respective cells 260a-260 b.

An anode feed-through or penetration 250 a-250 b according to someembodiments may be affixed to a respective tab 220 a-220 b, for exampleby laser welding or another of numerous possible attachment methods aswill be apparent to one having ordinary skill in the art. Where a tab220 a-220 b covers all or a portion of the width of a respective cell260 a-260 b, multiple feed-throughs or penetrations 250 a-250 b may bepossible within a cell, allowing for higher current capacity, betterconductive efficiency, or less residual heat within a cell versus atypical design which may include only a single feed-through orpenetration or very limited possible penetration area.

In other embodiments, a similar improvement to current capacity orconductive efficiency may be realized by increasing the size of afeed-through or penetration, for example by using long feed-throughs orpenetrations 250 a-250 b positioned inside a substantial portion of awidth of a face of a respective battery cell 260 a-260 b. In someembodiments, an enlarged feed-through or penetration 250 a-250 b may beaffixed to a respective tab 220 a-220 b at multiple points, or via acontinuous attachment method such as a continuous longitudinal weldalong a length of a feed-through or penetration 250 a-250 b.

Example cells 260 a-260 b may include one or more respective seals 240a-240 b. According to some embodiments, a seal 240 a-240 b may surrounda respective feed-through or penetration 250 a-250 b, for example toprevent electrolytes from escaping a respective battery cell 260 a-260 bvia an opening in the cell casing fabricated to accommodate an intrusionof a respective feed-through or penetration 250 a-250 b. A seal 240a-240 b according to some embodiments may be made at least in part of aPerfluoroalkoxy alkane (“PFA”) material or another suitable material aswill be apparent to one having ordinary skill in the art.

A cell 260 a-260 b may include a respective backstop feature 280 a-280 bto better accommodate shear forces as a result of battery cells beingcompressed together according to some embodiments. Backstop feature 280a-280 b may include a staggered “staircase” or other suitable structurebuilt into an insulating layer or cell casing of a respective cell 260a-260 b. Although a simple stair structure is illustrated in FIG. 2 ,one of ordinary skill in the art will understand that many differentsuitable structures may be employed to accommodate increased shearforces.

A cell 260 a-260 b according to some embodiments may include arespective flexure feature 290 a-290 b to add flexibility to arespective tab 220 a-220 b for accommodating shear forces as a result ofbattery cells being compressed together. As illustrated in the examplecells of FIG. 2 , flexure feature 290 a-290 b is represented as a notchin respective tab 220 a-220 b, however one of ordinary skill in the artwill appreciate that a tab 220 may be fabricated using any of manypossible structures with similar results.

FIG. 3A is an isometric external view of a battery cell including ananode tab according to some embodiments. Cell 330 includes a conductingtab 320, which according to some embodiments covers a majority of a topand a majority of a side face 325 of cell 330.

An insulating layer 310 covers the remainder of the exterior portion ofcell 330 visible in FIG. 3A. As described elsewhere herein, aninsulating layer may be applied to electrically isolate tab 310 from theconductive casing of cell 330, which may be at cathode potential.

FIG. 3B is an another isometric external view of the battery cell 330 ofFIG. 3A according to some embodiments. FIG. 3B shows a face 335 of cell330 opposite face 325 illustrated at FIG. 3A. Cathode casing 340 may beexposed across part or all of face 335 according to some embodiments.The example cell 330 of FIG. 3B illustrates cathode casing exposedacross a majority of face 335.

FIG. 3C is an isometric external view of three battery cells in seriescontact according to some embodiments. According to some embodiments,cells 370 a-370 c may be similar or identical to battery cell 330 ofFIGS. 3A and 3B. Tabs 350 a-350 c of respective cells 370 a-370 c may beconfigured to contact a cathode casing (not pictured in FIG. 3C) of anadjacent cell. For example, as illustrated at FIG. 3C, tab 350 a of cell370 a may contact a cathode casing of cell 370 b, while tab 350 b ofcell 37 b may contact a cathode casing of cell 370 c.

Insulating layers 360 a-360 c of respective cells 370 a-370 c arevisible at FIG. 3C. As described elsewhere herein, insulating layers 360may be applied to electrically isolate tabs 350 a-350 c from respectivecathode casings (not illustrated at FIG. 3C) of cells 370 a-370 c.

FIGS. 4A and 4B show isometric external views of opposite sides of anadditional example battery cell according to some embodiments. Examplecell 430 according to some embodiments includes a tab 420 which formspart or a majority of one face of battery cell 430. Tab 420 according tosome embodiments may be an anode tab as described in detail herein.Means of electrical connection of tab 420 to active material of cell 430similar to other example cells described in detail herein may befabricated within the cell rather than, for example, the external tab ofcells 260 a-260 b of FIG. 2 .

The remainder of the exterior boundary of example cell 430 may be acathode casing 440 as shown in FIGS. 4A and 4B. A seal 450 may bepositioned to electrically isolate tab 420 from cathode casing 440. Seal450 according to various embodiments may be any nonconducting material,for example a PFA material, rubberized material, or other materialsuitable for forming an insulating layer described elsewhere herein.

According to some embodiments, tab 420 may form an extruded section. Inother embodiments, tab 420 may be recessed from or flush with the planeof cathode casing 440. In some example embodiments, an extruded tab 420may aid in maintaining electrical contact with a cathode casing of anadjacent cell. In other embodiments, a similar function may beaccomplished by combining a recessed tab 420 section with an extrudedcathode casing section at a face of cell 430 opposite tab 420.

FIG. 4C is another isometric external view of three example batterycells in series contact according to some embodiments. Example cells 470a-470 c may be similar or identical to battery cell 430 of FIGS. 4A and4B. Tabs 450 a-450 c (450 a and 450 b not visible) of respective cells470 a-470 c may be configured to contact a cathode casing 460 a-460 c ofrespective adjacent cells 470 a-470 c. For example, as illustrated atFIG. 4C, tab 450 a (not visible) of cell 470 a may contact cathodecasing 460 b of cell 470 b, while tab 450 b (not visible) of cell 470 bmay contact cathode casing 460 c of cell 470 c.

FIG. 5A illustrates a cross section of a battery cell in contact with acold plate according to some embodiments. Example cell 560 may include atab 520, cell casing 530, insulating layer 510 and conductive layer 570similar to those described in detail elsewhere herein.

Example cell 560 may additionally include a lower cold plate 540 incontact with a bottom face of example cell 560 for conducting heat awayfrom the cell. Lower cold plate 540 may be formed of aluminum or anothermaterial suitable for conducting heat, as one having ordinary skill inthe art would understand. A second conductive layer 580 may be appliedbetween cell 560 and lower cold plate 540 according to some embodimentsto aid transmission of heat between the cell 560 and lower cold plate540.

FIG. 5B illustrates a cross section of a battery cell in contact withmultiple cold plates according to some embodiments. Example cell 565 mayinclude a tab 525, cell casing 535, insulating layer 515, and conductivelayer 575 as described in detail elsewhere herein. Example cell 565 mayadditionally include a lower cold plate 545 similar to the lower coldplate described with reference to FIG. 5A and a second conductive layer585 positioned between cell 565 and lower cold plate 545.

Example cell 565 according to some embodiments may further include anupper cold plate 555 positioned in contact with a top face of examplecell 565 for conducting heat away from cell 565. A third conductivelayer 595 may be positioned between cell 565 and cold plate 555 foraiding transmission of heat to cold plate 555.

In some embodiments, cold plates may be positioned on different faces ofexample cells besides the configurations illustrated herein. In stillother embodiments, cold plates may be replaced with another means ofconducting heat away from a cell, such as thermal channels, a heatexchange system, or liquid cooling system of a surrounding battery pack,as one having ordinary skill in the art will recognize.

FIG. 6A illustrates a cross section of a battery cell including a fuseaccording to some embodiments. Example cell 660 according to someembodiments may include a tab 620, cell casing 630, insulating layer610, and conductive layer 670 similar to those described in detailelsewhere herein.

Example cell 660 of FIG. 6A may further include a fuse 650 forrestricting flow of current through cell 660 under certaincircumstances. For example, a fuse 650 may be configured to restrictflow of electric current when cell 660 experiences an overcurrentcondition, overvoltage condition, overtemperature condition, or othercondition as would be apparent to one having ordinary skill in the art.

Fuse 650 of example cell 660 is illustrated as being integrated into tab620. However, one of ordinary skill in the art will recognize that fuse650 may be implemented in a different manner or location. For example,fuse 650 according to some embodiments may be integrated into cellcasing 630 or at any other suitable location within a conducting path ofcell 660.

FIG. 6B illustrates a cross section of a battery cell including adischarge element according to some embodiments. Example cell 665according to some embodiments includes a tab 625, a cell casing 635, aninsulating layer 615, and a conductive layer 675 similar to thosedescribed in detail elsewhere herein.

Example cell 665 of FIG. 6B may additionally include a discharge element655 for bleeding excess charge from battery cell 665. Cell discharge maybe desirable for several reasons, such as battery balancing or storagesafety. Discharge element 655 may include, for example, one or moreresistors or transistors such as field-effect transistors. One ofordinary skill in the art will recognize that other means of discharginga cell may be employed according to materials available and designrequirements.

Example cell 665 of FIG. 6B may additionally include a lower cold plate645 in contact with discharge element 655 and cell 665. The conductiveproperties of cold plate 645 may aid in efficient discharge of cell 665.Cell 665 according to some embodiments may additionally include aconductive layer 685 positioned between discharge element 655 and lowercold plate 645.

FIG. 7 is a high-level flowchart illustrating various methods offabricating a battery cell according to some embodiments. Variousembodiments may include several or all of the steps described hereinwith reference to FIG. 7 , and the order of some steps may be changedaccording to various embodiments.

Step 710 of process 700 includes affixing at least one anode protrusionat least partially within a battery-active-material assembly. Thebattery-active-material assembly according to some embodiments may be aprismatic or cylindrical “jelly roll” type cathode/separator/anodeassembly as described elsewhere herein, or another suitable assembly.According to some embodiments, an anode protrusion affixed at step 710may be similar to those described with reference to FIG. 2 .

Step 720 of process 700 includes forming a seal about the anodeprotrusion. The seal plugs any excess opening in a battery casing aroundthe anode protrusion, and may in some embodiments be similar to theelectrolyte seals described elsewhere herein.

Step 730 includes forming a cathode casing about the seal andbattery-active material assembly. The cathode casing may be similar tothose described in detail herein. For example, the cathode casing mayform a majority of the exterior can of the battery cell. In otherembodiments, the casing may instead be at anode potential. In someembodiments, part of the casing may be a nonconducting material or at aneutral potential.

Step 740 includes fabricating an anode terminal. The anode terminal maybe of various designs and configurations and described in detail andsuggested herein, for example an anode tab. Step 750 may includeattaching the anode terminal to the battery cell, for example by laserwelding to one or more anode protrusions according to variousembodiments.

Step 760 includes applying an insulating layer similar to various layersdescribed herein. For example, an insulating layer may be appliedbetween the cathode casing and the anode terminal. An insulating layermay additionally be applied to other parts of a battery cell, forexample to electrically insulate a battery at the end of a string from awall of a battery pack enclosure.

Step 770 includes applying at least one conduction enhancement layer.For example, as described herein, a conduction enhancement layer may beapplied to an external surface of an anode terminal tab at a locationthat contacts a cathode casing of an adjacent cell, as described infurther detail elsewhere herein. Various embodiments may includeadditional conductive layers, for example between a cell and a coldplate or other battery cooling means.

Step 780 includes applying at least one adhesive layer. An adhesivelayer may be applied, for example, between an anode terminal tab and aninsulating layer, or between a cold plate and a battery cell. Theadhesive layer according to various embodiments may be apressure-sensitive adhesive as described herein or another suitablematerial.

The methods described herein may be implemented in software, hardware,or a combination thereof, in different embodiments. In addition, theorder of the blocks of the methods may be changed, and various elementsmay be added, reordered, combined, omitted, modified, etc. Variousmodifications and changes may be made as would be obvious to a personskilled in the art having the benefit of this disclosure. The variousembodiments described herein are meant to be illustrative and notlimiting. Many variations, modifications, additions, and improvementsare possible. Accordingly, plural instances may be provided forcomponents described herein as a single instance. Boundaries betweenvarious components, operations and data stores are somewhat arbitrary,and particular operations are illustrated in the context of specificillustrative configurations. Other allocations of functionality areenvisioned and may fall within the scope of claims that follow. Finally,structures and functionality presented as discrete components in theexample configurations may be implemented as a combined structure orcomponent. These and other variations, modifications, additions, andimprovements may fall within the scope of embodiments as defined in theclaims that follow.

What is claimed is:
 1. A battery, comprising: a positive active material and a negative active material, the positive and negative active materials arranged in a prismatic configuration; a cathode casing in electrical communication with the positive active material, the cathode casing forming a majority of the surface area of an external can of the battery; an anode terminal in electrical communication with the negative active material, the anode terminal comprising a conducting tab; an insulating layer, the insulating layer arranged to electrically isolate the cathode casing from the anode terminal.
 2. The battery of claim 1, wherein at least a portion of the anode terminal is external to the cathode casing and planar with respect to a face of the battery.
 3. The battery of claim 1, further comprising an anode penetration assembly in electrical communication with the anode terminal, wherein the anode penetration assembly intrudes into an interior of the battery at a plurality of points.
 4. The battery of claim 1, further comprising a pressure-sensitive adhesive applied between the anode terminal and the insulating layer.
 5. The battery of claim 1, wherein the anode terminal further comprises a fuse for interrupting a current flow via the anode terminal when the battery experiences an overcurrent condition.
 6. The battery of claim 1, further comprising a cell discharge resistor, the cell discharge resistor contacting a conducting portion of the battery and a current discharge plate.
 7. The battery of claim 1, further comprising an electrolyte seal positioned about an opening in the cathode casing, the opening associated with a protrusion of a portion of the anode terminal into the interior of the cathode casing.
 8. The battery of claim 7, wherein the electrolyte seal comprises perfluoroalkoxy alkane (PFA).
 9. The battery of claim 1, further comprising a conduction enhancement layer between the anode terminal and a second cathode casing of a second battery.
 10. The battery of claim 9, wherein the conduction enhancement layer comprises a contact aiding material.
 11. The battery of claim 9, wherein the conduction enhancement layer comprises a metallurgical plating.
 12. The battery of claim 1, further comprising: a positive current collector in electrical communication with the cathode casing.
 13. The battery of claim 1, further comprising: a negative current collector in electrical communication with an anode of another battery.
 14. The battery of claim 1, further comprising a heat dissipation element, the heat dissipation element in contact with the anode terminal.
 15. The battery of claim 14, wherein the heat dissipation element comprises a cold plate.
 16. The battery of claim 1, wherein the battery is rectangular in shape.
 17. The battery of claim 1, wherein a portion of the external can of the battery comprises an insulating material.
 18. The battery of claim 1, further comprising a first heat dissipation element that is in contact with the anode terminal, and a second heat dissipation element that is in contact with a face of the external can of the battery, the face situated on a side of the battery opposite to the anode terminal.
 19. The battery of claim 1, further comprising a discharge element including a transistor, the discharge element configured to bleed excess charge from the battery.
 20. The battery of claim 19, further comprising a conductive layer situated between the discharge element and a heat dissipation element that is electrically conductive. 